Metal Strip Segmentation for Continuous Casting Interruptions
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Solution Overview
Problem
Continuous casting and rolling processes face interruptions due to malfunctions, leading to significant downtimes, material damage, and production losses, as existing solutions require manual intervention and are not efficient for recycling scrap metal.
Innovation Solution
Implementing a method that involves cutting the metal strip between the casting machine and finishing mill, storing it, and then cutting it into manageable pieces using a separating device and driver, allowing for automatic or partial automation of the process to resume operations quickly and safely, with the ability to recycle scrap metal easily.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the continuous casting and rolling process operates without interruption, then productivity is improved, but reliability deteriorates due to potential malfunctions and material jams
Solution Approach 1:
The patent divides the continuous strip into separate bundles by introducing cutting devices that can sever the strip at predetermined locations. This segmentation allows the system to operate continuously while creating manageable sections that can be independently handled if malfunctions occur, thus maintaining both productivity and reliability.
Solution Approach 2:
The patent implements preliminary cutting of the strip into bundles before rolling operations. By pre-segmenting the material, the system prepares for potential interruptions in advance, allowing quick isolation of affected sections without stopping the entire continuous casting process, thereby maintaining productivity while improving reliability.
2Reliability
If the strip is cut into bundles before rolling, then reliability is improved by preventing material jams, but productivity deteriorates due to additional cutting operations
Solution Approach 1:
The patent combines the cutting operation with the existing rolling process by integrating cutting devices into the rolling line. The cutting is performed in conjunction with the rolling operations rather than as a separate preliminary step, thereby improving reliability through bundle creation without significantly impacting overall productivity.
Solution Approach 2:
The patent maintains continuous operation by performing cutting actions during the rolling process rather than stopping the line. The cutting devices operate in synchronization with the rolling mill, ensuring that the useful action of material processing continues uninterrupted while still achieving the reliability benefit of bundle segmentation.
3Reliability
If manual intervention is used to clear material jams, then reliability is improved by removing obstacles, but loss of time increases due to manual work requirements
Solution Approach 1:
The patent implements automated systems that can detect and clear material jams without manual intervention. The cutting devices and control systems automatically identify problematic sections and sever the strip to remove jams, allowing the system to service itself and maintain reliability without incurring time losses associated with manual clearance operations.
4Reliability
If the casting machine stops to prevent solidification, then reliability is improved by avoiding mold damage, but productivity deteriorates due to production interruptions
Solution Approach 1:
The patent segments the continuous strip into bundles that can be independently managed. If the casting machine needs to stop to prevent solidification, only the current bundle is affected rather than the entire continuous strand, allowing the mold to be protected while minimizing the impact on overall productivity through localized interruption.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes downtime, reduces manual labor, and enables efficient recycling of scrap metal by cutting and storing the strip in a way that allows for quick resumption of production and easy melting of small pieces, maintaining a compact system design.
Implementation Method 1
a driver being arranged behind the separating device in the conveying direction, which driver is designed to convey the band into the band store, and wherein the driver is also designed to convey the band back to the separating device
Implementation Method 2
cutting the band at a point between the casting machine and the finishing mill by means of a cutting device
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for producing a metal strip (1) in a continuous casting and rolling process, wherein first a slab is cast in a casting machine and the slab is fed to a finishing rolling mill arranged downstream in a conveying direction (F) of the strip (1) and is rolled there. According to the invention, in order to enable the recycling of scrap while achieving a compact design, the following steps are performed in the event of a planned or unplanned production interruption in the finishing rolling mill: a) cutting through the strip (1) at a location (4) between the casting machine (2) and the finishing rolling mill by means of a cutting device (5); b) conveying the part of the strip (1) following the cut into a strip store (6) by means of a driver (7), wherein the driver (7) is arranged after the cutting device (5) in the conveying direction (F); c) cutting through the strip (1) again by means of the cutting device (5) and cutting up the following part of the strip (1) into pieces by means of the cutting device (5); d) cutting up the stored strip segment into pieces preferably having a defined longitudinal extent. The invention further relates to a device for performing the method.